Method and apparatus for brushless electrical machine control

ABSTRACT

A variable reluctance motor load mapping apparatus includes a frame, an interface disposed on the frame configured for mounting a variable reluctance motor, a static load cell mounted to the frame and coupled to the variable reluctance motor, and a controller communicably coupled to the static load cell and the variable reluctance motor, the controller being configured to select at least one motor phase of the variable reluctance motor, energize the at least one motor phase, and receive motor operational data from at least the static load cell for mapping and generating an array of motor operational data look up tables.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.16/793,623, filed on Feb. 18, 2020, now U.S. Pat. No. 11,181,582, whichis a continuation of U.S. patent application Ser. No. 14/540,077, filedNov. 13, 2014, now U.S. Pat. No. 10,564,221, which claims priority fromand benefit of U.S. provisional application No. 61/903,745, filed Nov.13, 2013, the disclosures of which are incorporated herein by referencein their entireties.

BACKGROUND 1. Field

The exemplary embodiments generally relate to electrical machines and,more particularly, to control of the electrical machines.

2. Brief Description of Related Developments

Generally variable (or switched) reluctance motors (VRM) are beingsought as a cost effective alternative to brushless direct currentmotors. Variable reluctance motors do not require magnets and theirmechanical construction is simple however, the usage of variablereluctance motors for precision control remains challenging due to, forexample, high non-linear relationships between the phase current, rotorelectrical position, torque and geometry. One of the main challenges inprecision control of variable reluctance motors is providing a smoothand ripple free pre-specified torque at any given position of the rotor.The torque ripple inherent with variable reluctance motors may be due tomodeling uncertainties. As a result, the performance of variablereluctance motors may be dependent on the existence of an accuratecommutation model that relates desired torque with phase currents andposition. In addition, typical feedback loops, as in conventional offthe shelf amplifiers, are generally designed and optimally tuned for afixed inductance, which variable reluctance motors generally do nothave. In variable reluctance motors changes in the motor coil or windinginductances are expected because this is the primary mechanism ofmechanical torque generation for variable reluctance motors.

In, for example, robot servo applications, the servo performance may beinfluenced by the dynamic response of the actuator or motor. A slowmotor response may limit the speed of response of the servo system. Inrobot servo applications using motors as actuators, it is typicallyassumed that the motor response is at least an order of magnitude fasterthan that of the servo loop and is often ignored in the system model,which is particularly the case with brushless direct current motors.Variable reluctance motors however, have a relatively slower responsethat may warrant certain adjustments to the commutation strategy tocompensate for the slow response. As such, substantially instantaneoustorque control may be required for variable reluctance motor drive usein position servo applications. Instantaneous torque control may beprovided through, for example, digital electronic controllers that maycontrol the current through each motor phase as a function of motorposition and required instantaneous torque. The determination of currentrequired in each motor phase as a function of motor position and torquemay be referred to as current commutation. In three phase permanentmagnet brushless motors (where the three phase currents are 120 degreesapart) the current through each motor winding is sinusoidal and is auniquely defined function of rotor position and torque. On the otherhand, the phase currents in a variable reluctance motor are notsinusoidal, but rather have a shape that is derived from motor torquecurves. The motor torque curves for a motor are either measured ordetermined from a finite element analysis of a motor model. In general,for a switched reluctance motor the torque may be a function of motorposition as well as each of the phase currents. The purpose of currentcommutation is to determine a required current in each motor phase as afunction of motor position and motor torque.

It would be advantageous to minimize the effects of torque ripple on thecontrol of variable reluctance motors. It would also be advantageous toprovide an optimal commutation scheme that provides an approach tocomputing currents in each motor phase so that one or more optimizationcriteria are accomplished. It would be further advantageous to provide acontrol system that alleviates the dependency of an accurate commutationmodel for variable reluctance motors.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing aspects and other features of the disclosed embodiment areexplained in the following description, taken in connection with theaccompanying drawings, wherein:

FIGS. 1A-1D are schematic illustrations of substrate processing tools inaccordance with aspects of the disclosed embodiment;

FIGS. 1E and 1F are schematic illustrations of portions of a variablereluctance motor in accordance with aspects of the disclosed embodiment;

FIG. 2 illustrates an exemplary table in accordance with aspects of thedisclosed embodiment;

FIG. 3 illustrates another exemplary table in accordance with aspects ofthe disclosed embodiment;

FIG. 4 is a schematic illustration of a portion of the variablereluctance motor shown in FIGS. 1E and 1F in accordance with aspects ofthe disclosed embodiment;

FIG. 5 is a schematic illustration of an iso-torque value generationstation in accordance with aspects of the disclosed embodiment;

FIG. 5A illustrates a flow chart in accordance with aspects of thedisclosed embodiment;

FIG. 6 illustrates a portion of an iso-torque curve table in accordancewith aspects of the disclosed embodiment;

FIG. 7 illustrates an exemplary comparison table in accordance withaspects of the disclosed embodiment;

FIGS. 8A and 8B illustrate exemplary phase current tables with respectto rotor position in accordance with aspects of the disclosedembodiment;

FIGS. 9A and 9B illustrate exemplary motor input power tables withrespect to rotor position in accordance with aspects of the disclosedembodiment;

FIGS. 10A and 10B illustrate portions of iso-torque curve tables inaccordance with aspects of the disclosed embodiment;

FIGS. 11A and 11B are schematic illustrations of a portion of a variablereluctance motor in accordance with aspects of the disclosed embodiment;

FIGS. 12 and 13 illustrate a schematic diagram of a transport apparatusand control system therefor in accordance with aspects of the disclosedembodiment;

FIGS. 14 and 15 illustrate exemplary comparison tables in accordancewith aspects of the disclosed embodiment;

FIG. 16 illustrates an exemplary comparison table in accordance withaspects of the disclosed embodiment; and

FIG. 17 illustrates a flow chart in accordance with aspects of thedisclosed embodiment.

DETAILED DESCRIPTION

In accordance with aspects of the disclosed embodiment, a switchedreluctance brushless electrical machine or motor and optimal commutationschemes or strategies therefore are provided. Commutation schemes orstrategies refer to the determination of current in each motor phase asa function of motor position and desired torque. Although the aspects ofthe disclosed embodiment will be described with reference to thedrawings, it should be understood that the aspects of the disclosedembodiment can be embodied in many forms. In addition, any suitablesize, shape or type of elements or materials could be used.

Referring to FIGS. 1A-1D, there are shown schematic views of substrateprocessing apparatus or tools incorporating the aspects of the disclosedembodiment as disclosed further herein.

Referring to FIGS. 1A and 1B, a processing apparatus, such as forexample a semiconductor tool station 1090 is shown in accordance with anaspect of the disclosed embodiment. Although a semiconductor tool isshown in the drawings, the aspects of the disclosed embodiment describedherein can be applied to any tool station or application employingrobotic manipulators. In this example the tool 1090 is shown as acluster tool, however the aspects of the disclosed embodiment may beapplied to any suitable tool station such as, for example, a linear toolstation such as that shown in FIGS. 1C and 1D and described in U.S.patent application Ser. No. 11/442,511, entitled “Linearly DistributedSemiconductor Workpiece Processing Tool,” filed May 26, 2006, thedisclosure of which is incorporated by reference herein in its entirety.The tool station 1090 generally includes an atmospheric front end 1000,a vacuum load lock 1010 and a vacuum back end 1020. In other aspects,the tool station may have any suitable configuration. The components ofeach of the front end 1000, load lock 1010 and back end 1020 may beconnected to a controller 1091 which may be part of any suitable controlarchitecture such as, for example, a clustered architecture control. Thecontrol system may be a closed loop controller having a mastercontroller, cluster controllers and autonomous remote controllers suchas those disclosed in U.S. patent application Ser. No. 11/178,615,entitled “Scalable Motion Control System,” filed Jul. 11, 2005, thedisclosure of which is incorporated by reference herein in its entirety.In other aspects, any suitable controller and/or control system may beutilized.

In one aspect, the front end 1000 generally includes load port modules1005 and a mini-environment 1060 such as for example an equipment frontend module (EFEM). The load port modules 1005 may be box opener/loaderto tool standard (BOLTS) interfaces that conform to SEMI standardsE15.1, E47.1, E62, E19.5 or E1.9 for 300 mm load ports, front opening orbottom opening boxes/pods and cassettes. In other aspects, the load portmodules may be configured as 200 mm wafer interfaces or any othersuitable substrate interfaces such as for example larger or smallerwafers or flat panels for flat panel displays. Although two load portmodules are shown in FIG. 1A, in other aspects any suitable number ofload port modules may be incorporated into the front end 1000. The loadport modules 1005 may be configured to receive substrate carriers orcassettes 1050 from an overhead transport system, automatic guidedvehicles, person guided vehicles, rail guided vehicles or from any othersuitable transport method. The load port modules 1005 may interface withthe mini-environment 1060 through load ports 1040. The load ports 1040may allow the passage of substrates between the substrate cassettes 1050and the mini-environment 1060. The mini-environment 1060 generallyincludes any suitable transfer robot 1013 which may incorporate one ormore aspects of the disclosed embodiment described herein. In one aspectthe robot 1013 may be a track mounted robot such as that described in,for example, U.S. Pat. No. 6,002,840, the disclosure of which isincorporated by reference herein in its entirety. The mini-environment1060 may provide a controlled, clean zone for substrate transfer betweenmultiple load port modules.

The vacuum load lock 1010 may be located between and connected to themini-environment 1060 and the back end 1020. It is noted that the termvacuum as used herein may denote a high vacuum such as 10-5 Torr orbelow in which the substrate are processed. The load lock 1010 generallyincludes atmospheric and vacuum slot valves. The slot valves may providethe environmental isolation employed to evacuate the load lock afterloading a substrate from the atmospheric front end and to maintain thevacuum in the transport chamber when venting the lock with an inert gassuch as nitrogen. The load lock 1010 may also include an aligner 1011for aligning a fiducial of the substrate to a desired position forprocessing. In other aspects, the vacuum load lock may be located in anysuitable location of the processing apparatus and have any suitableconfiguration.

The vacuum back end 1020 generally includes a transport chamber 1025,one or more processing station(s) 1030 and any suitable transfer robot1014 which may include one or more aspects of the disclosed embodimentsdescribed herein. The transfer robot 1014 will be described below andmay be located within the transport chamber 1025 to transport substratesbetween the load lock 1010 and the various processing stations 1030. Theprocessing stations 1030 may operate on the substrates through variousdeposition, etching, or other types of processes to form electricalcircuitry or other desired structure on the substrates. Typicalprocesses include but are not limited to thin film processes that use avacuum such as plasma etch or other etching processes, chemical vapordeposition (CVD), plasma vapor deposition (PVD), implantation such asion implantation, metrology, rapid thermal processing (RTP), dry stripatomic layer deposition (ALD), oxidation/diffusion, forming of nitrides,vacuum lithography, epitaxy (EPI), wire bonder and evaporation or otherthin film processes that use vacuum pressures. The processing stations1030 are connected to the transport chamber 1025 to allow substrates tobe passed from the transport chamber 1025 to the processing stations1030 and vice versa.

Referring now to FIG. 1C, a schematic plan view of a linear substrateprocessing system 2010 is shown where the tool interface section 2012 ismounted to a transport chamber module 3018 so that the interface section2012 is facing generally towards (e.g. inwards) but is offset from thelongitudinal axis X of the transport chamber 3018. The transport chambermodule 3018 may be extended in any suitable direction by attaching othertransport chamber modules 3018A, 3018I, 3018J to interfaces 2050, 2060,2070 as described in U.S. patent application Ser. No. 11/442,511,previously incorporated herein by reference. Each transport chambermodule 3018, 3019A, 3018I, 3018J includes any suitable substratetransport 2080, which may include one or more aspects of the disclosedembodiment described herein, for transporting substrates throughout theprocessing system 2010 and into and out of, for example, processingmodules PM. As may be realized, each chamber module may be capable ofholding an isolated or controlled atmosphere (e.g. N2, clean air,vacuum).

Referring to FIG. 1D, there is shown a schematic elevation view of anexemplary processing tool 410 such as may be taken along longitudinalaxis X of the linear transport chamber 416. In the aspect of thedisclosed embodiment shown in FIG. 1D, tool interface section 12 may berepresentatively connected to the transport chamber 416. In this aspect,interface section 12 may define one end of the tool transport chamber416. As seen in FIG. 1D, the transport chamber 416 may have anotherworkpiece entry/exit station 412 for example at an opposite end frominterface station 12. In other aspects, other entry/exit stations forinserting/removing workpieces from the transport chamber may beprovided. In one aspect, interface section 12 and entry/exit station 412may allow loading and unloading of workpieces from the tool. In otheraspects, workpieces may be loaded into the tool from one end and removedfrom the other end. In one aspect, the transport chamber 416 may haveone or more transfer chamber module(s) 18B, 18 i. Each chamber modulemay be capable of holding an isolated or controlled atmosphere (e.g. N2,clean air, vacuum). As noted before, the configuration/arrangement ofthe transport chamber modules 18B, 18 i, load lock modules 56A, 56B andworkpiece stations forming the transport chamber 416 shown in FIG. 1D ismerely exemplary, and in other aspects the transport chamber may havemore or fewer modules disposed in any desired modular arrangement. Inthe aspect shown, station 412 may be a load lock. In other aspects, aload lock module may be located between the end entry/exit station(similar to station 412) or the adjoining transport chamber module(similar to module 18 i) may be configured to operate as a load lock. Asalso noted before, transport chamber modules 18B, 18 i have one or morecorresponding transport apparatus 26B, 26 i, which may include one ormore aspects of the disclosed embodiment described herein, locatedtherein. The transport apparatus 26B, 26 i of the respective transportchamber modules 18B, 18 i may cooperate to provide the linearlydistributed workpiece transport system 420 in the transport chamber. Inthis aspect, the transport apparatus 26B may have a general SCARA armconfiguration (though in other aspects the transport arms may have anyother desired arrangement such as a frog-leg configuration, telescopicconfiguration, bi-symmetric configuration, etc.). In the aspect of thedisclosed embodiment shown in FIG. 1D, the arms of the transportapparatus 26B may be arranged to provide what may be referred to as fastswap arrangement allowing the transport to quickly swap wafers from apick/place location as will also be described in further detail below.The transport arm 26B may have a suitable drive section, such as thatdescribed below, for providing each arm with any suitable number ofdegrees of freedom (e.g. independent rotation about shoulder and elbowjoints with Z axis motion). As seen in FIG. 1D, in this aspect themodules 56A, 56, 30 i may be located interstitially between transferchamber modules 18B, 18 i and may define suitable processing modules,load lock(s), buffer station(s), metrology station(s) or any otherdesired station(s). For example the interstitial modules, such as loadlocks 56A, 56 and workpiece station 30 i, may each have stationaryworkpiece supports/shelves 56S, 56S1, 56S2, 30S1, 30S2 that maycooperate with the transport arms to effect transport or workpiecesthrough the length of the transport chamber along linear axis X of thetransport chamber. By way of example, workpiece(s) may be loaded intothe transport chamber 416 by interface section 12. The workpiece(s) maybe positioned on the support(s) of load lock module 56A with thetransport arm 15 of the interface section. The workpiece(s), in loadlock module 56A, may be moved between load lock module 56A and load lockmodule 56 by the transport arm 26B in module 18B, and in a similar andconsecutive manner between load lock 56 and workpiece station 30 i witharm 26 i (in module 18 i) and between station 30 i and station 412 witharm 26 i in module 18 i. This process may be reversed in whole or inpart to move the workpiece(s) in the opposite direction. Thus, in oneaspect, workpieces may be moved in any direction along axis X and to anyposition along the transport chamber and may be loaded to and unloadedfrom any desired module (processing or otherwise) communicating with thetransport chamber. In other aspects, interstitial transport chambermodules with static workpiece supports or shelves may not be providedbetween transport chamber modules 18B, 18 i. In such aspects, transportarms of adjoining transport chamber modules may pass off workpiecesdirectly from end effector or one transport arm to end effector ofanother transport arm to move the workpiece through the transportchamber. The processing station modules may operate on the substratesthrough various deposition, etching, or other types of processes to formelectrical circuitry or other desired structure on the substrates. Theprocessing station modules are connected to the transport chambermodules to allow substrates to be passed from the transport chamber tothe processing stations and vice versa. A suitable example of aprocessing tool with similar general features to the processingapparatus depicted in FIG. 1D is described in U.S. patent applicationSer. No. 11/442,511, previously incorporated by reference in itsentirety.

The optimal commutation schemes described herein are schemes thatprovide approaches to computing currents in each phase of the brushlesselectrical machine so that one or more optimization criteria areaccomplished. In the aspects of the disclosed embodiment the optimalcommutation schemes may substantially maximize torque subject to certainconstraints that will be described in greater detail below. Thecommutation schemes described herein may be applicable to any suitablemotor type but are illustrated herein with respect to, for example, avariable reluctance motor for exemplary purposes. FIGS. 1E and 1Fillustrate portions of a brushless electrical machine having a passiverotor in accordance with an aspect of the disclosed embodiment. Theexemplary configuration of a direct drive brushless electrical machineillustrated in FIGS. 1E and 1F is representative of such machines havinga rotary configuration, and used for convenience in describing aspectsof the embodiment herein. It is noted that the aspects of the embodimentas described further below apply in a similar manner to a linearbrushless electrical machine. In one aspect, as noted above, thebrushless electrical machine having a passive rotor may be a variable orswitched reluctance motor 100 connected to any suitable controller 400which may be configured for controlling operation of the motor 100 asdescribed herein. In one aspect, the controller 400 may have adistributed architecture substantially similar to that described in U.S.Pat. No. 7,904,182 entitled “Scalable Motion Control System”, thedisclosure of which is incorporated by reference herein in its entirety.

Here the variable reluctance motor 100 includes a housing 101, at leastone stator 103 disposed within the housing and at least one rotor 102corresponding to each of the at least one stator 103. Each of the atleast one stator 103 may have any suitable number of salient (e.g. nomagnets) stator poles 103P each having a motor winding or coil 104. Eachof the at least one rotor 102 may also have any suitable number ofsalient rotor poles 102P so that the rotor is configured to form aclosed magnetic flux circuit with the stator. For exemplary purposesonly, the variable reluctance motor 100 is illustrated as a four phasemotor having six rotor poles and eight stator poles but in other aspectsthe variable reluctance motor may have any suitable number of motorphases, any suitable number of rotor poles and any suitable number ofstator poles. Here the at least one rotor 102 is disposed within orotherwise substantially surrounded by a respective stator 103 but inother aspects the stator may be disposed within or otherwisesubstantially surrounded by a respective rotor. Also, in this aspect theone or more stator/rotor pairs may be arranged in a stack (e.g. axiallyspaced next to each other along an axis of rotation of the variablereluctance motor 100) however, in other aspects the stator/rotor pairsmay be arranged in a nested configuration where each stator/rotor pairis radially nested or otherwise substantially surrounded by anotherstator/rotor pair. The variable reluctance motor 100 may be configuredfor operation in atmospheric environments and/or vacuum environmentswhere the stationary parts of the motor are isolated from the vacuumatmosphere as described in, for example, U.S. provisional patentapplication No. 61/903,813 entitled “Sealed Robot Drive” filed on Nov.13, 2013, the disclosure of which is incorporated by reference herein inits entirety. The variable reluctance motor may also include features asdescribed in U.S. provisional patent application No. 61/903,792 entitled“Axial Flux Motor” filed on Nov. 13, 2013, the disclosure of which isincorporated by reference herein in its entirety.

As may be realized each of the at least one rotor 102 may be coupled toa respective drive shaft of any suitable drive shaft assembly 110. Inthis aspect the drive shaft assembly 110 is illustrated as a coaxialdrive shaft assembly having two drive shafts but in other aspects theremay be more or less than two drive shafts where each drive shaftcorresponds to a respective rotor and stator pair (e.g. motor) of thebrushless electrical machine. In still other aspects the drive shaftassembly may include individual drive shafts or coaxial drive shaftsthat are located side by side. As may be realized, the drive shaftassembly 110 may be connected to any suitable device, such as a robottransport device 111. The robotic transport device 111 may be forexample, any suitable transport arm including but not limited to abi-symmetric robot arm assembly, a SCARA type robot arm assembly, atelescoping robot arm assembly, a robot arm assembly having a lostmotion switch or any other suitable robot arm assembly that includes oneor more robot arms and utilizes a coaxial or side by side drive shaft.Referring now to FIGS. 2 and 3 , respective torque versus positioncurves are illustrated for different current magnitudes across onesingle motor phase in accordance with aspects of the disclosedembodiment. In one aspect, also referring to FIGS. 1E and 1F, each motorphase may include two coils 104 wired in series and positioneddiametrically opposite to each other, however in other aspects eachmotor phase may include any suitable number of coils wired in anysuitable manner and located in any suitable position relative to oneanother. Generally, two of the motor phases may be energized to generatea desired or otherwise predetermined torque magnitude and directionexcept at, for example, electrical positions where only one motor phasecontributes to the motor torque as shown in FIG. 3 where only a singlemotor phase is energized when, for example, the rotor is at about 0, 15and 30 degrees. It should be understood that the rotor positions ofabout 0, 15 and 30 degrees are exemplary only and in other aspects therotor positions where only a single motor phase is energized may be anysuitable rotor positions which may depend on the number of stator androtor poles and other motor configuration factors.

Generally several approaches have been proposed to define desired phasecurrents or a desired commutation strategy to achieve a desired amountof torque for any given time and rotor position. These approachesattempt to minimize torque ripple by assuming that each phase torquecontribution can be independently quantified by measurements such asthose illustrated in FIG. 2 . However, these approaches generallyneglect the effect of the neighboring phase once the neighboring phasegets energized. For example, the inductance of one of the active coilswill change as the neighboring coil is energized. As such, the shape ofthe torque curve illustrated in, for example, FIGS. 2 and 3 may changedepending on the current of the neighboring phase. Not considering thechange in inductance of the active coil when a neighboring coil isenergized may result in torque ripple of the variable reluctance motor100.

In one aspect of the disclosed embodiment an approach for obtaining acommutation strategy is provided that may naturally capture the effectof mutual inductance (e.g. the effect on inductance of one coil when anadjacent coil is energized) and as such, substantially minimizes theeffect of torque ripple in the commutation of variable reluctancemotors. Referring now to FIGS. 4 and 5 , in one aspect the commutationstrategy includes providing an apparatus, e.g. torque value generatingstation 510, to which the variable reluctance motor 100 is connected(FIG. 5A, Block 550). This station or apparatus provides a system forempirically characterizing the relationship between current, positionand desired torque (or force) (e.g. rotational or linear motorarrangements as may apply) of the brushless electrical machine. Thevariable reluctance motor 100 may be run in any suitable manner at anarray of phase currents (e.g. one or more phase commutating phasecurrents are varied to produce a predetermined torque) (FIG. 5A, Block551) and/or an array of rotor electrical positions (e.g. the phasecurrents are measured for different torques at different rotorpositions) (FIG. 5A, Block 552) that represent the operating range ofthe variable reluctance motor 100. The measured currents, torques androtor electrical positions are recorded (FIG. 5A, Block 553) and torquecurves (e.g. values) at the predetermined electrical positions and phasecurrent combinations can be recorded and/or mapped by any suitablecontroller 400′ (e.g. an array of torque-current tables for given rotorpositions are generated) (FIG. 5A, Block 554). In one aspect the torquevalue generating station 510 may include any suitable frame 520 to whichany suitable load cell 500 and the variable reluctance motor 100 aremounted. In one aspect the load cell 500 may be a static load cell. Thevariable reluctance motor 100 may be coupled to the load cell 500 in anysuitable manner for providing operating resistance to the variablereluctance motor 100. The variable reluctance motor 100 and/or the loadcell 500 may be communicably connected to, for example, controller 400′for operation of the variable reluctance motor 100 andrecordation/mapping of the motor torque and more specifically, for anysuitable number of position sufficient to describe the relation betweenthe iso-torque curves, corresponding phase currents and rotor positionsfor a full rotor cycle or period (e.g. 360 degrees of electricalposition). These values may be formatted, in any manner suitable forprogramming a controller, such as for example, a look up table as willbe described further below. It is noted that in accordance with anotheraspect, the data or values characterizing the relationship betweengenerated torque (force), current and position of the variablereluctance motor of desired form and characteristics may be generatedusing modeling techniques such as numerical methods or finite elementmodeling.

In this aspect a stator 103 of the variable reluctance motor 100 isshown in FIG. 4 . Here the stator coils and an exemplary wiring of thestator coils are illustrated schematically and the rotor has beenomitted for clarity. As described above, each motor phase A-D includestwo diametrically opposed coils that are wired in series. For example,motor phase A includes coils 104A1 and 104A2, motor phase B includescoils 104B1 and 104B2, motor phase C includes coils 104C1 and 104C2 andmotor phase D includes coils 104D1 and 104D2. Again, in other aspectsthe motor may have more or less than four phases arranged and wired inany suitable manner. The terminal leads of each motor phase may be wiredto any suitable respective current source, such as for example I₁ and I₂with respect to phases A and B. In one aspect each current source can beindependently set (e.g. through any suitable controller 400′) togenerate a desired current through is respective phase. At a given rotorposition, phases A and B are energized at predetermined currents and theload cell 500 registers the resultant static torque. At each rotorposition and at a given current I₁ in phase A, the current I₂ in phase Bis varied from, for example, about 0 to any suitable predeterminedmaximum current value. In one aspect the predetermined maximum currentvalue may be a worst case operating range for the variable reluctancemotor 100. This procedure (e.g. varying the phase B current for constantvalues of rotor position and phase A current) is repeated for an arrayof current I₁ and I₂ as well as an array of rotor electrical positionsthat, for example, represent an operating range of the variablereluctance motor 100. For example the operating range may be from about0 to about 360 electrical degrees. At each point in the array, thestatic torque is measured and mapped with respect to the correspondingrotor electrical positions and corresponding phase current combinationsto form an array of iso-torque curves (FIG. 5A, Block 553). As notedbefore, in other aspects the characterization data for the motor may begenerated by modeling or simulation. An exemplary mapping or table ofiso-torque curves (i.e. curves of constant torque at a given electricalposition of the rotor) is illustrated in FIG. 6 . It is noted that whileiso-torque curves are described and shown herein the use of the term“curves” and the illustration thereof is for exemplary purposes only andin other aspects the iso-torque curves, which relate phase currents totorque and rotor position, can be represented in any suitable tabularform that includes phase current values, torque values and rotorposition values. In FIG. 6 the iso-torque curves correspond to a rotorelectrical position of 5 degrees but it should be understood thatiso-torque curves may be generated for more than one electrical positionof the rotor.

It is noted that the generation of the iso-torque tables described aboveis repeatable for any given motor or family of motors (e.g. two or moremotors having substantially the same operating characteristics such asnumber of stator poles, number of rotor poles, air gap between thestator and rotor poles, etc.). As such, the iso-torque tables describedabove may be generated for any suitable motor having any suitablepredetermined operating characteristics and the commutation schemesdescribed herein with respect to the aspects of the disclosed embodimentmay be applied to any of these suitable motors.

Referring again to FIG. 1E, the controller 400 may include a positioncontrol loop (FIGS. 12 and 13 ), described below, that may be configuredto specify a desired or otherwise predetermined amount of torque at agiven rotor electrical position and time. Any suitable commutationalgorithm, such as those described below, may specify the current in oneof the phases A-D. Tables such as those generated above, a portion ofsuch table is shown in FIG. 6 , may be resident in a memory accessibleby or contained in the controller 400 for providing the controller 400with a respective current of the additional phase. For example, thecommutation algorithm may specify a phase current i₁ for phase A and thecontroller may be configured to obtain a respective phase current i₂ forphase B for any given torque and electrical angle of the rotor from thetable so that the torque ripple of the variable reluctance motor isreduced. FIG. 7 illustrates an exemplary comparison plot of torqueversus rotor position with respect to a conventional uncompensatedtorque ripple motor commutation and compensated torque ripple motorcommutation (e.g. in accordance with aspects of the disclosedembodiment). As can be seen in FIG. 7 , compensating for torque ripple(see curve 700) in accordance with aspects of the disclosed embodimentsubstantially reduces the effects of torque ripple (the nature of whichcomes from the mutual effect of adjacent phases being energized at thesame time, as evidenced in FIG. 7 where the torque of both curves isequal when only one phase is energized).

In accordance with aspects of the disclosed embodiment, referring againto FIGS. 1E and 1F and as described herein, the torque for the motor 100may be a function of motor position as well as each of the phasecurrents. Also, there may not be a unique set of phase currents for agiven torque (see for example, the table in FIG. 6 ) which illustrates asubstantially infinite number of combinations of possible phase currentvalues to achieve the given torque. Referring also to FIG. 8A an exampleof phase current variation is illustrated in phases A and B of, forexample, the motor 100 at a constant torque. In the rotor positioninterval ranging from 0 to 15 degrees, only phases A and B are energizedand the currents in phase C and D (see also FIG. 4 ) are substantiallyzero. Here phase A may be referred to as the dominant phase as it isdriving the rotor 102 and phase B may be referred to as a latent phasewhose current is increasing or ramping up to drive rotor as the rotor ismoving between stator poles 103P. As the rotor pole passes the givenstator pole 103P, phase B becomes the dominant phase and phase A becomesthe latent phase such that the phase current in phase A decreases orramps down. As can be seen in FIG. 8A, in one aspect, the ramping upand/or down of the phase currents when driving the rotor 102 may beprovided as a linear shape function so that the change in current islinear. In other aspects, referring to FIG. 8B, another possiblesolution to the variation of phase currents is shown as a function ofrotor position to yield a constant torque. Here the ramping up and/ordown of the phase currents is provided as a quadratic shape function. Asmay be realized the ramping up and down of the phase currents may beprovided as any suitable shape function. As may also be realized theshape function used to ramp up the phase current may be different fromthe shape function used to ramp down the phase current.

Still referring to FIGS. 4, 8A and 8B, as noted above, examples of phasecurrent variation at a constant torque in phases A and B are illustratedas the rotor 102 spins from about 0 to about 15 degrees. In otheraspects the rotor may spin between any suitable angles or degree of arc.As also noted above, the phase current of phases C and D aresubstantially zero in this interval from about 0 to about 15 degrees. Inone aspect, for the motor 100 the phase current signature may beperiodic about every 15 degrees of rotor rotation and phase currents maybe generated for a about 0 to about 15 degree interval of rotorrotation. As can be seen in the Figs. phases A and B are active in theabout 0 to about 15 degree interval, and in the about 15 to about 30degree interval phases B and C are active and so on. The profile of thecurrent in phase B in the about 15 to about 30 degree interval may besubstantially similar to that shown for phase A in FIGS. 8A and 8B (e.g.in the about 0 to about 15 degree interval) and the phase current inphase C in the about 15 to about 30 degree interval may be substantiallysimilar to that shown for phase B in FIGS. 8A and 8B. As may berealized, substantially the same periodicity relationship applies toother phase pairs B-C, C-D and D-A as the rotor spins. In other aspectsany suitable periodicity relationship(s) may be provided for the phasepairs. In this aspect, at any given rotor position, at most two phasesare active and at every about 15 degree interval, one of the phasesbecomes inactive and a new phase becomes active.

In one aspect the commutation schemes described herein may use one ormore torque tables such as those described above with respect to FIG. 6, which tabulate motor torque as a function of phase currents i_(A) andi_(B) and motor position θ for any suitable rotor interval, such as theabout 0 to about 15 degree interval noted above. In one aspect thetorque table may be represented analytically asT=T(θ,i _(A) ,i _(B))  [1]

where the torque T is position dependent. In other aspects, the torquetable may be experimentally measured (e.g. as described above withrespect to torque curve generation station 510). In still other aspectsthe torque tables may be computed through, for example, finite elementanalysis of a motor model. In yet other aspects the torque tables may begenerated in any suitable manner. It is noted that while the commutationschemes described herein will be described with respect to the about 15degree interval noted above, in other aspects the commutation schemesdescribed herein may be applied to any suitable interval.

With respect to the about 15 degree periodicity (which in other aspectsmay be any suitable interval) appropriate boundary conditions for thephase currents i_(A) and i_(B) may be established such asi _(A)=0 at θ=15 deg  [2]andi _(B)=0 at θ=0 deg  [3]

To solve for the two phase currents shown in, for example, FIGS. 3A and3B the about 15 degree interval may be divided substantially in half orinto sub-intervals, one half being from about 0 to about 7.5 degrees andthe other half being from about 7.5 to about 15 degrees. In each of thesub intervals one of the phase currents is defined by, for example, anysuitable shape function as described above and the remaining phasecurrent may be determined from, for example, any suitable torque tablesuch as that shown in FIG. 6 .

Referring to FIGS. 9A and 9B, the total electrical power consumed Pc bythe energized phases (in this example phases A and B are energized) isillustrated as the rotor spins at any suitable rpm which, for exemplarypurposes in this example, is about 60 rpm. The power curve in FIG. 9Acorresponds to the phase currents in FIG. 8A and the power curve in FIG.9B corresponds to the phase currents in FIG. 8B. Here, for exemplarypurposes, a constraint may be placed on the available power of the motorsuch that the available power is about 540 W. In other aspects the powermay be constrained to any suitable value such as, for example, the powerrating of the motor being commutated by the schemes described herein.The torque may be adjusted such that the peak power consumption fallsbelow the about 540 W power constraint. As can be seen in FIGS. 9A and9B, in this example, at about 60 rpm the torque corresponding to thepower constraint of about 540 W is about 7.1 Nm for the linear shapefunction of FIG. 8A and about 7.2 Nm for the quadratic shape function ofFIG. 8B. It is noted that, in one aspect, the slope of the shapefunctions may also be constrained, such as with respect to a voltage ofthe bus supplying power to the phases as will be described below.

In one aspect of the disclosed embodiment, an approach to determiningphase currents that maximize motor torque for a given limit on inputpower may be provided where the shape functions described above withrespect to FIGS. 8A and 8B are replaced with a constraint(s) on motorpower consumption. In general, the voltage drop across a single phase ofthe motor may be written as

$\begin{matrix}{V = {{Ri} + \frac{d\;{\lambda\left( {\theta,i} \right)}}{dt}}} & \lbrack 4\rbrack\end{matrix}$

where V is the voltage across the phase, i is the phase current, R isthe phase resistance and

$\frac{d{\lambda\left( {\theta,i} \right)}}{dt}$is the flux linkage rate in terms of motor angular position θ andcurrent i. Also,λ(θ,i)=L(θ,i)i  [5]

where L(θ,i) is the inductance. As such, the voltage across the phasecan be rewritten as

$\begin{matrix}{V = {{Ri} + {\frac{d\lambda}{d\theta}\overset{.}{\theta}} + {\frac{d\lambda}{di}\frac{di}{dt}}}} & \lbrack 6\rbrack\end{matrix}$

and multiplying both sides of equation [6] by the current i yields thepower equality

$\begin{matrix}{{Vi} = {R^{2} + {\frac{d\lambda}{d\theta}\overset{.}{\theta}i} + {\frac{d\lambda}{di}\frac{di}{dt}i}}} & \lbrack 7\rbrack\end{matrix}$

As such, based on e.g. equation [7] the constraint on the motor powerconsumption or total power can be written in terms of phase currentsi_(A) and i_(B), phase resistance R, and flux linkage λ_(A) (i_(A), θ)and λ_(B) (i_(B), θ) respectively as

$\begin{matrix}{{{i_{A}^{2}R} + {i_{B}^{2}R} + {i_{A}\frac{d\lambda_{A}}{di_{A}}\frac{{di}_{A}}{dt}} + {i_{B}\frac{d\lambda_{B}}{{di}_{B}}\frac{di_{B}}{dt}} + {T\overset{.}{\theta}}} < P_{\max}} & \lbrack 8\rbrack\end{matrix}$

where “T{dot over (θ)}” represents the mechanical power output of themotor (T is the motor torque and {dot over (θ)} is the angularvelocity), i_(A) ²R and i_(B) ²R represent the resistive power loss inthe motor windings or coils and

$i_{A}\frac{d\lambda_{A}}{di_{A}}\frac{{di}_{A}}{dt}{and}i_{B}\frac{d\lambda_{B}}{{di}_{B}}\frac{di_{B}}{dt}$represent the magnetic field energy stored in the motor. It is notedthat in one aspect the torque may be specified by, for example,kinematic analysis of the transport device 111 (FIG. 1 ) as described inInternational Application Number PCT/US2012/052977 (WO publicationnumber 2013/033289) entitled “Time-Optimal Trajectories for RoboticTransfer Devices” and filed on Aug. 30, 2012 and U.S. patent applicationSer. No. 13/614,007 entitled “Method for Transporting a Substrate with aSubstrate Transport” and filed on Sep. 13, 2012 the disclosures of whichare incorporated herein by reference in their entireties. In otheraspects the torque (and/or the angular velocity) may be obtained bymotor sensors in real time and the power may be adjusted by, forexample, controller 400 so that the total power remains substantiallybelow P_(max). Given the torque of the motor, the phase currents i_(A)and i_(B) can be determined from the iso-torque tables described above.In other aspects the phase currents can be determined in any suitablemanner. In one aspect, the constraint equation [8] can be combined withthe iso-torque tables and the phase current boundary conditions ofequations [2] and [3] to determine the phase currents i_(A) and i_(B)(or any other suitable phase currents for the phase current pairs notedabove) in, for example, the about 0 to about 15 degree rotor position(or any other suitable rotor position).

In another aspect of the disclosed embodiment, an approach todetermining phase currents that maximize motor torque for a given limiton input power may be provided where the shape functions described abovewith respect to FIGS. 8A and 8B are replaced with a constraint(s) onphase voltage V_(bus). For example, given the voltage across the phaseas described above in equation [6] a constraint on voltage in each ofthe phases (e.g. in this example phases A and B) can be written as

$\begin{matrix}{{{i_{A}R} + {\frac{d\lambda_{A}}{d\theta}\overset{.}{\theta}} + {\frac{d\lambda_{A}}{di_{A}}\frac{{di}_{A}}{dt}}} < V_{bus}} & \lbrack 9\rbrack\end{matrix}$ $\begin{matrix}{and} & \end{matrix}$ $\begin{matrix}{{{i_{B}R} + {\frac{d\lambda_{B}}{d\theta}\overset{.}{\theta}} + {\frac{d\lambda_{B}}{{di}_{B}}\frac{di_{B}}{dt}}} < V_{bus}} & \lbrack 10\rbrack\end{matrix}$

where

$\frac{d\lambda}{d\theta}\overset{.}{\theta}{and}\frac{d\lambda}{di}\frac{di}{dt}$can be determined from, for example, the iso-torque tables, motormodels, empirically, from motor sensors or in any other suitable manner.In one aspect, the constraint equation [8] can be combined with theiso-torque tables and the phase current boundary conditions of equations[2] and [3] to determine the phase currents i_(A) and is (or any othersuitable phase currents for the phase current pairs noted above) in, forexample, the about 0 to about 15 degree rotor position (or any othersuitable rotor position). In one aspect, the constraint equations [9]and [10] can be combined with the iso-torque tables and the phasecurrent boundary conditions of equations [2] and [3] to determine thephase currents i_(A) and i_(B) (or any other suitable phase currents forthe phase current pairs noted above) in, for example, the about 0 toabout 15 degree rotor position (or any other suitable rotor position).

In one aspect of the disclosed embodiment a further commutation schememay be provided where a minimum power P_(min) is achieved as describedbelow. Here a desired torque is known from, for example, the positioncontrol loop of the transport device 111 (FIG. 1 ) as noted above.Referring to FIGS. 10A and 10B, iso-torque tables (which aresubstantially similar to those described above) may be used to determinethe phase currents, such as i_(A) and i_(B), in any suitable manner fora given torque and motor rotor position. For example, in one aspect aunique set of phase currents i_(A) and i_(B) (see also FIG. 6 ) can beidentified along the desired iso-torque line such that the a minimumdissipative power is achieved within the phases A and B. In otheraspects the minimum power P_(min) may be determined through numericalanalysis, empirically, etc.). Once the minimum power is achieved thecorrespondent phase currents i_(A) and i_(B) can be recorded, such asfor example into a table for the given desired torque and at therespective rotor position. Equations [9] and [10] above may be used toverify that the phase currents i_(A) and i_(B) associated with P_(min)for a given torque and torque position can comply with the constraintimposed by the bus voltage V_(bus).

In another aspect of the disclosed embodiment, a real time comparatorcommutation scheme may be used to operate the motor 100. For example,the controller 400 may include a current feedback loop that accounts forthe changes of the coil inductance during real time operation of themotor 100. This current feedback loop may allow for torque compensationthat addresses the effects of torque ripple in the motor 100. Forexample, referring to FIGS. 12 and 13 the controller 400 may include amemory 400M, a position loop module 1200, a commutation loop module1201, a current loop module, a torque ripple estimator, and aninductance model module. The motor 100 may include a motor phase plantmodule 100M1 and a motor magnetic circuit plant module 100M2. Here, forexample, the desired trajectory and actual state feedback are input intothe position loop module 1200 which is configured to calculate thedesired torque to be applied by the motor 100. The desired torque isinput into the commutation loop module 1201 which may be configured touse the actual position and velocity of the motor (as determined by,e.g., motor sensors) to calculate the desired phase currents to beimposed in the motor 100. The desired phase currents are input into thecurrent loop module 1202 which may employ the actual phase current asfeedback to calculate the phase voltage at the terminals of therespective coils 104 of the motor 100.

The inductance model module 1204 (in which the inductance model can berepresented as

$\left. {\frac{d\lambda}{di} = {L\left( {\theta,i} \right)}} \right)$may be configured to account for changes in the inductance of the motor100 in terms of, for example, the motor's actual position and actualphase current so that the current loop module can better utilize itscontrol gains for a more realistic inductance and better cope with thelarge variation in the inductance that exist in a variable reluctancemotor. As may be realized, the phase voltage generated by the currentloop module 1202 may result in some torque ripple. To attenuate thistorque ripple a phase voltage correction signal may be applied to thephase voltage. The torque ripple estimator 1203 may use one or more ofan estimated inductance, the actual phase current, the flux linkagerate, the actual position, actual velocity, and desired torque tocalculate in real time the appropriate phase voltage correction thatwill result in a reduction of the torque ripple in the output of themotor magnetic circuit 100M2 where the actual torque is generated.

The flux linkage rate (which can be written as

$\left. \frac{d\lambda}{dt} \right)$used by the torque ripple estimator may be measured in any suitablemanner such as with the sensor or pick up coil 1100 shown in FIGS. 11Aand 11B, which may be located on or adjacent the respective coil. Inother aspects the sensor 1100 may be located at any suitable positionfor measuring the flux linkage. The sensor 1100 may be an independentcoil positioned such that as the phase coil 104 is energized (e.g. as aresult of commutation) the magnetic flux linkage generated within thestator pole 103P is induced in the sensor 1100. The rate of change ofthe flux linkage with the resistance, current and terminal voltageacross the sensor 1100 coil is defined by equation [4] above. Byconnecting the sensor 1100 to a high impedance channel (such as ananalog to digital converter or any other suitable high impedancechannel) the associated current can be neglected and what remains is theterminal voltage (see equation [11] below) that is a substantiallydirect measurement of the rate of change of flux linkage across thestator pole.

Each motor phase may have its own sensor 1100 configured to provide aflux linkage rate for each rotor position.

$\begin{matrix}{V = \frac{d\lambda}{dt}} & \lbrack 11\rbrack\end{matrix}$

It is noted that the torque ripple compensation performed by the torqueripple estimator includes the ability to have an indirect measure of theactual torque generated by the motor output. This indirect measure ofthe actual torque is compared against the desired torque so that thetorque ripple estimator can calculate the phase voltage correction thatwill cause the actual torque to approach the desired torque. Theindirect measure of the actual torque can be derived from the followingequation

$\begin{matrix}{{\frac{d\lambda}{d\theta}\overset{.}{\theta}i} = {{Torque}x\overset{.}{\theta}}} & \lbrack 12\rbrack\end{matrix}$

Using equation [12] and the partial derivative of the flux linkage (seeequation [5] above) the indirect measure of the actual torque can becalculated from the following equation

$\begin{matrix}{{Torque} = {\left( {\frac{d\lambda}{dt} - {\frac{d\lambda}{di}\frac{di}{dt}}} \right)\frac{i}{\overset{.}{\theta}}}} & \lbrack 13\rbrack\end{matrix}$

where the flux linkage

$\frac{d\lambda}{dt}$is measured as described above (see equation [11]), the inductance

$\frac{d\lambda}{di} = {L\left( {\theta,i} \right)}$is determined with a lookup table, a model empirically or in any othersuitable manner and the expression

$\frac{i}{\overset{.}{\theta}}$can be calculated from, for example, the current and velocity feedbackor in any other suitable manner.

A resultant phase current can be generated from the modified phasevoltage (e.g. the phase voltage modified after the phase voltagecorrection is applied by the torque ripple estimator 1203) which in turncan be used to generate the actual torque provided by the motor magneticcircuit 100M2. The inertial plant 1205 (which may be substantiallysimilar to the transport device 111 described above) reacts to theactual torque applied by generating the respective acceleration,velocity and position of the inertial plant 1205. The acceleration,velocity and position states of the inertial plant are then fed back tothe appropriate control loop modules as shown in FIGS. 12 and 13 .

In the aspects of the disclosed embodiments described herein thetorque-current-position relationship reflects motor torque as a functionof motor position and phase currents under, for example, steady stateconditions where a desired torque and rotor position are fixed in time.If the torque or rotor position where to vary with time, as is the casein a robotic application, the validity of using static torquerelationships may be determined by the speed of response of the motordynamics. A measure of the motor dynamics is the speed of torque stepresponse of the motor. FIG. 14 illustrates a torque output of abrushless DC motor commanded to a torque of about 3 Nm. The motor torquestep response (e.g. dynamic response time) may be measured in anysuitable manner. FIG. 14 also illustrates the torque step response of avariable reluctance motor (with a similar form factor to the brushlessDC motor). It can be seen in FIGS. 14 and 15 that the brushless DC motorhas a faster response time than the variable reluctance motor. It isnoted that the torque curve in a variable reluctance motor may beginwith a substantially zero slope while the torque curve on the brushlessDC motor may begin with a non-zero slope. This is because in a switchedreluctance motor the torque-current relationship is quadratic while thetorque-current relationship in the brushless DC motor is linear. Thus,it is expected that in comparison to the brushless DC motor, theconventional switched reluctance motor may have an inherently slowresponse time in the vicinity of zero currents and torques. In oneaspect of the disclosed embodiment the system and method (such as may beembodied in a suitable algorithm) allows for the switched reluctancemotor to respond faster in the near zero torque/current ranges asdescribed further below. In accordance with aspects of the disclosedembodiment the dynamic response of the variable reluctance motor may beimproved as indicated next. Given the following equations

$\begin{matrix}{T_{VRM} \propto {i^{2}{f(\theta)}}} & \lbrack 14\rbrack\end{matrix}$ $\begin{matrix}{\left. {{\frac{d}{dt}T_{VRM}} \propto {{2{f(\theta)}i\frac{d}{dt}i} + {i^{2}\frac{d}{dt}{f(\theta)}\overset{.}{\theta}}}}\Rightarrow{{\frac{d}{dt}T_{VRM}} \approx {0{at}i}} \right. = 0} & \lbrack 15\rbrack\end{matrix}$

where T_(VRM) is the Variable (or Switched) Reluctance Motor Torque, “i”is the phase current, “θ” is the rotor position and “f(θ)” represents adependency on rotor position; it follows from equation [15] that thedynamic response of a variable reluctance reluctance motor, such asmotor 100, may be a function of phase current; the dynamic response ofthe variable reluctance motor (dT_(VRM)/dt) increases with an increasein the phase current; and the dynamic response is substantially zerowhen there is no current through the coils 104 (FIGS. 1E and 1F).

In this aspect of the disclosed embodiment, referring again to FIGS. 1Eand 1F, the commutation scheme is to have a non-zero phase current atzero torque. The non-zero phase current may create a “bias torque” inother phases of the motor so that the dynamic response time of the motoris increased (e.g. made faster) (e.g. the gradient between T=0 and thedemanded torque T_(demand) is changed). In a four phase motor, such asmotor 100, energizing two phases (the phases being energized aredetermined by rotor position) results in a torque in one direction andenergizing the remaining two phases results in a torque in the oppositedirection. Nominally, only two phases are energized depending on thedirection of torque. Here, the commutation scheme energizes all fourphases such that when the torque demanded of the motor is substantiallyzero, the positive torque due to two phases A, B is balanced by thenegative torque due to the remaining two phases C, D and the net torqueis zero. Energizing all four phases A-D in a balanced manner (e.g. sothe net torque is substantially zero or balanced) substantially providesa non-zero current even at a zero torque state of the motor 100 andimproves the response time of the variable reluctance actuator (or theeffective bandwidth) as expressed by equation [15].

As an example, if at a given motor position, phases A and B contributeto a positive motor torque and phases C and D contribute to a negativemotor torque, and the desired torque is T and ΔT is a chosen bias torqueoffset value, and function ƒ represents the torque-current-positionrelationships, the phase currents can be defined as(i _(A) ,i _(B))=ƒ(θ,T+ΔT)  [18]and(i _(C) ,i _(D))=ƒ(θ,−ΔT)  [19]

where i_(A), i_(B), i_(C) and i_(D) are the phase currents in phases A-Drespectively. Here the net motor torque may be substantially equal to Tand the bias torque offset value ΔT may be chosen in any suitable mannerto be an arbitrarily small value. The bias torque offset value ΔT mayresult in an increase in phase currents that may be determined fromcommutation relationships, such as those described above. FIG. 16illustrates the motor torque step response to a commanded torque of, forexample, about 3 Nm for a brushless DC motor, a variable reluctancemotor with no phase current bias (basic VRM), a variable reluctancemotor with constant phase current bias (e.g. the bias substantially doesnot change with actuation of the motor when a non-balanced torque, i.e.T_(demand), is produced) and a variable reluctance motor with variablephase current bias (e.g. the bias changes with actuation of the motorwhen a non-balanced torque, i.e. T_(demand), is produced). FIG. 16illustrates for comparative purposes, the response profiles to desiredtorque of the different motor configurations. The dashed portions of theplots represent approximate performance to the steady state operatingconditions and are included for completeness, but otherwise areunrelated to the aspects of the features described herein. As can beseen in FIG. 16 , the response (rise) time of the variable reluctancemotor with a constant phase current bias decreases (i.e. fasterresponse) over the basic VRM (no torque bias) and the response time ofthe variable reluctance motor with variable phase current bias decreasesover the response time of the variable reluctance motor with constantphase current bias. In order to minimize a loss of motor power theoffset torque may be set to a non-zero value as required and asdetermined by the application. In one aspect the non-zero phase currentmay be applied to produce the offset torque at any suitable time (FIG.17 , Block 1700) such as within a predetermined time period or at apredetermined time prior to an expected time the demanded T_(demand) isneeded (i.e. the offset torque may be considered a pre-torque that isapplied just before the demanded torque is needed), rather than beingapplied coincidentally with the demanded torque. Also, as shown in FIG.16 , a time-varying torque offset profile may result in a faster dynamicresponse than a constant torque offset. In one aspect, to enable afaster dynamic response in, for example, robotic transport applicationsthe controller, such as controller 400, may be configured to ramp up thebias torque (e.g. set to a predetermined start value) at the start of orjust prior to (e.g. with pre-torque command to produce the pre-torquedescribed above) the robotic manipulator (such as transport device 111in FIG. 1E) movement (FIG. 17 , Block 1701) and ramped down (e.g.decreased to a value lower than the predetermined start value) as themove begins and/or before the demanded or maximum torque and/oracceleration (e.g. the acceleration of a substrate carried by thetransport device) is reached (FIG. 17 , Block 1702). This ramping up andramping down of the bias torque may substantially prevent or otherwisereduce any “overshoot” (e.g. moving past) of the robotic manipulatorwith respect to a desired pick or place target. In one aspect the rampup and ramp down bias torque profiles can be chosen to be several ordersof magnitude shorter in duration than the robotic manipulator moveduration (e.g. the ramp up and ramp down durations are negligiblecompared to the duration of the robotic manipulator move). In otheraspects the ramp up and ramp down profiles may have any suitableduration. In one aspect the ramp up and ramp down bias torque profilesmay have substantially zero slopes at zero torque and the duration ofthe ramp up and ramp down may be determined by available bus voltageand/or motor coil inductance. As may be realized, the bias torque may beprovided at more than one region of the robotic manipulator move (e.g.at the start of the move, at the end of the move and/or at one or morepoints in between start and end of the move). In one aspect the ramp upof the torque bias may be a gradual increase of the bias torque. Inanother aspect the ramp down of the bias torque may depend on a desireddynamic response time.

As described above, the controller 400 (FIG. 1E) may have a distributedarchitecture that includes high level controllers and lower levelcontrollers similar to that described in U.S. Pat. No. 7,904,182(previously incorporated herein by reference in its entirety). In oneaspect the iso-torque tables may be resident in one or more high levelcontrollers such that aspects of the commutation schemes, which mayinclude any suitable calculations, comparisons, sending commands to thevariable reluctance motors, monitoring operational characteristics ofthe variable reluctance motors, modifying the torque output of themotor, etc. may be performed by one or more lower level controllers.

As may be realized, the aspects of the disclosed embodiments may beemployed individually or in any suitable combination.

In accordance with one or more aspects of the disclosed embodiment avariable reluctance motor load mapping apparatus is provided. Theapparatus includes a frame, an interface disposed on the frameconfigured for mounting a variable reluctance motor, a static load cellmounted to the frame and coupled to the variable reluctance motor, and acontroller communicably coupled to the static load cell and the variablereluctance motor. The controller being configured to select at least onemotor phase of the variable reluctance motor, energize the at least onemotor phase, and receive motor operational data from at least the staticload cell for mapping and generating an array of motor operational datalook up tables.

In accordance with one or more aspects of the disclosed embodiment, thecontroller is configured to receive motor operational data from thestatic load cell and the variable reluctance motor where the motoroperational data includes at least one of a static motor torque, arespective phase current for each of the at least respective motor phaseand a motor rotor position.

In accordance with one or more aspects of the disclosed embodiment, thecontroller is configured to generate from the motor operational dataconstant torque values as a function of rotor position and phasecurrents for adjacent motor phases.

In accordance with one or more aspects of the disclosed embodiment, thecontroller is configured to generate minimum power values associatedwith each constant torque value and provide the minimum power values ina look up table.

In accordance with one or more aspects of the disclosed embodiment, thecontroller is configured to generate motor operational data look uptables where each motor operational data look up table includes an arrayof constant torque values and corresponding phase currents for a givenrotor position.

In accordance with one or more aspects of the disclosed embodiment, thecontroller is configured to, for an array of predetermined rotorpositions corresponding to each predetermined rotor position, energizeadjacent motor phases at an array of predetermined current combinationsand receive, from the static load cell, a resultant static torque foreach of the predetermined current combinations.

In accordance with one or more aspects of the disclosed embodiment, thecontroller is configured to, for each predetermined rotor position and apredetermined first motor phase current, vary an additional motor phasecurrent or any suitable combinations of additional phase currents.

In accordance with one or more aspects of the disclosed embodiment, thecontroller is configured to generate torque values from the resultantstatic torque and map the torque values and associated phase currentcombinations for each predetermined rotor position to form the array ofmotor operational data look up tables.

In accordance with one or more aspects of the disclosed embodiment amethod for characterizing the relationship between torque, current andposition of determining motor load for a variable reluctance motor isprovided. The method includes providing a static load cell, coupling thevariable reluctance motor to the static load cell, selecting at leastone motor phase of the variable reluctance motor, energizing the atleast one motor phase, receiving with a controller motor operationaldata from at least the static load cell, and mapping and generating withthe controller an array of motor operational data look up tables.

In accordance with one or more aspects of the disclosed embodiment, themethod further includes receiving with the controller motor operationaldata from the static load cell and the variable reluctance motor wherethe motor operational data includes at least one of a static motortorque, a respective phase current for each of the at least respectivemotor phase and a motor rotor position.

In accordance with one or more aspects of the disclosed embodiment, themethod includes generating, with the controller from the motoroperational data, constant torque values as a function of phase currentsand rotor position.

In accordance with one or more aspects of the disclosed embodiment, thecontroller is configured to generate minimum power values associatedwith each constant torque value and provide the minimum power values ina look up table.

In accordance with one or more aspects of the disclosed embodiment, eachmotor operational data look up table includes an array of constanttorque values and corresponding phase currents for a given rotorposition.

In accordance with one or more aspects of the disclosed embodiment, themethod includes energizing, with the controller, motor phases at anarray of predetermined current combinations for an array ofpredetermined rotor positions and receiving from the static load cell aresultant static torque for each of the predetermined currentcombinations and corresponding rotor positions.

In accordance with one or more aspects of the disclosed embodiment, themethod includes varying an additional motor phase current with thecontroller for each predetermined rotor position and a predeterminedfirst motor phase current.

In accordance with one or more aspects of the disclosed embodiment, themethod includes generating, with the controller, torque values from theresultant static torque and mapping the torque values and associatedphase current combinations for each predetermined rotor position to formthe array of motor operational data look up tables.

In accordance with one or more aspects of the disclosed embodiment, amethod includes coupling a load to an output shaft of a variablereluctance motor, generating an array of static torques on the outputshaft with the variable reluctance motor, adjusting a rotor position ofthe variable reluctance motor and recording, with a controller, motordata that includes a static torque value, rotor position, and phasecurrents for adjacent phases of the variable reluctance motor.

In accordance with one or more aspects of the disclosed embodiment, anarray of phase current combinations are recorded for adjacent phases foreach static torque value in the array of static torques.

In accordance with one or more aspects of the disclosed embodiment, anarray of static torques is generated for each rotor position in an arrayof rotor positions.

In accordance with one or more aspects of the disclosed embodiment, themethod includes mapping, with the controller, the array of statictorques and respective phase current combinations for each rotorposition to form a data look up table.

In accordance with one or more aspects of the disclosed embodiment, themethod includes energizing, with the controller, motor phases at anarray of predetermined current combinations for an array ofpredetermined rotor positions and recording resultant static torquevalues for each of the predetermined current combinations andcorresponding rotor positions.

In accordance with one or more aspects of the disclosed embodiment, themethod includes varying additional motor phase(s) current with thecontroller for each predetermined rotor position and a predeterminedfirst motor phase current.

In accordance with one or more aspects of the disclosed embodiment, anelectric machine is provided. The brushless electric machine includes apassive rotor with at least one rotor pole, a stator with at least onestator pole and a phase coil associated with each of the at least onestator pole, the phase coil being configured to establish a flux in amagnetic circuit between the rotor and stator where the rotor and statordefine a predetermined electric machine form factor, and a controllerconfigured to control current to each phase coil to generate apredetermined rotor torque, the controller being programmed with atleast predetermined constant torque values and related phase currentvalues so that the controller determines the current for each phase coilfor the generation of demanded rotor torque based on the predeterminedconstant torque values and related phase current values.

In accordance with one or more aspects of the disclosed embodiment thepredetermined constant torque values and related phase current valuesare empirically generated values.

In accordance with one or more aspects of the disclosed embodiment thepredetermined constant torque values and related phase current values ofthe brushless electric machine are generated from system modelinganalysis including one of a numerical modeling analysis or finiteelement analysis.

In accordance with one or more aspects of the disclosed embodiment, thebrushless electric machine comprises a variable reluctance motor that iseither rotary or linear configuration.

In accordance with one or more aspects of the disclosed embodiment, thebrushless electric machine comprises a variable reluctance motorconfigured for operation in a vacuum environment.

In accordance with one or more aspects of the disclosed embodiment, thepassive rotor is a coil-less and magnet-less rotor.

In accordance with one or more aspects of the disclosed embodiment, therelated phase current values are an array of phase current values sothat each phase current vector produces the predetermined constanttorque value common to the array of phase current values.

In accordance with one or more aspects of the disclosed embodiment, thecontroller is programmed with minimum power values associated with eachof the predetermined constant torque values.

In accordance with one or more aspects of the disclosed embodiment, thepredetermined constant torque values and related power values and phasecurrent values are commutative to every electric machine having asimilar form factor to the predetermined electric machine form factor.

In accordance with one or more aspects of the disclosed embodiment, therelated phase current values are premeasured current values.

In accordance with one or more aspects of the disclosed embodiment, theconstant torque values and related phase current values form one or morecommutation tables relating torque, rotor position and phase currentmagnitudes of motor phases.

In accordance with one or more aspects of the disclosed embodiment,variable reluctance motor controller is provided. The controllerincludes one or more sensors configured to measure predeterminedoperating characteristics of a variable reluctance motor, a current loopmodule configured to provide a phase voltage to the variable reluctancemotor, and a torque ripple estimator configured to generate, based onthe predetermined operating characteristics, and apply a substantiallyreal time phase voltage correction signal to the phase voltage toattenuate torque ripple effects of the variable reluctance motor.

In accordance with one or more aspects of the disclosed embodiment, thepredetermined operating characteristics include one or more of motorrotor position, motor rotor angular velocity, phase current for eachmotor phase, flux linkage rate and inductance of each phase.

In accordance with one or more aspects of the disclosed embodiment, theflux linkage rate is determined from a measured value.

In accordance with one or more aspects of the disclosed embodiment, theone or more sensors includes a pick up coil disposed at or adjacent eachmotor phase coil, the pick up coil being configured to measure a fluxlinkage associated with a respective motor phase coil.

In accordance with one or more aspects of the disclosed embodiment, theinductance is an estimated inductance obtained by the controller from alookup table or motor model.

In accordance with one or more aspects of the disclosed embodiment, thevariable reluctance motor controller includes an inductance moduleconfigured to determine changes in the inductance of the motor withrespect to motor rotor position and phase current.

In accordance with one or more aspects of the disclosed embodiment, thetorque ripple estimator comprises a real time comparator between adesired motor torque and an actual motor torque such that the phasevoltage correction signal causes the actual motor torque to approach thedesired motor torque.

In accordance with one or more aspects of the disclosed embodiment, abrushless electric machine is provided. The brushless electric machineincludes a passive rotor with at least one rotor pole, a stator with atleast one stator pole and a phase coil associated with each of the atleast one stator pole, the phase coil being configured to establish aflux in a magnetic circuit between the rotor and stator where the rotorand stator define a predetermined electric machine form factor, and acontroller configured to control current to each phase coil to generatea predetermined rotor torque, the controller being programmed so that anon-zero phase current is provided to each phase coil at a motor outputof zero torque.

In accordance with one or more aspects of the disclosed embodiment, thenon-zero phase current provided to each phase coil effects a net torquesubstantially equal to zero.

In accordance with one or more aspects of the disclosed embodiment, thenon-zero phase current effects a decrease in a dynamic response time(i.e. increased speed of response) of the brushless electric machine.

It should be understood that the foregoing description is onlyillustrative of the aspects of the disclosed embodiment. Variousalternatives and modifications can be devised by those skilled in theart without departing from the aspects of the disclosed embodiment.Accordingly, the aspects of the disclosed embodiment are intended toembrace all such alternatives, modifications and variances that fallwithin the scope of the appended claims. Further, the mere fact thatdifferent features are recited in mutually different dependent orindependent claims does not indicate that a combination of thesefeatures cannot be advantageously used, such a combination remainingwithin the scope of the aspects of the invention.

What is claimed is:
 1. A brushless electric machine load mappingapparatus comprising: a frame; an interface disposed on the frameconfigured for mounting a brushless electric machine; a static load cellmounted to the frame separate and distinct from the brushless electricmachine and coupled to the brushless electric machine so as to reactrotor torque of the brushless electric machine; and a controllercommunicably coupled to the static load cell and the brushless electricmachine, the controller being configured to receive from the static loadcell brushless electric machine operational data from at least a staticload cell static reaction of the rotor torque, of the brushless electricmachine, responsive for mapping and generating an array of brushlesselectric machine operational data look up tables.
 2. The apparatus ofclaim 1, wherein the controller is configured to receive brushlesselectric machine operational data from the static load cell where thebrushless electric machine operational data includes at least one of astatic rotor torque, a respective phase current for each of the at leastone respective brushless electric machine phase and a rotor position. 3.The apparatus of claim 1, wherein the controller is configured togenerate from the motor operational data constant torque values as afunction of rotor position and phase currents for adjacent motor phases.4. The apparatus of claim 3, wherein the controller is configured togenerate minimum power values associated with each constant torque valueand provide the minimum power values in a look up table.
 5. Theapparatus of claim 1, wherein the controller is configured to generatemotor operational data look up tables where each motor operational datalook up table includes an array of constant torque values andcorresponding phase currents for a given rotor position.
 6. Theapparatus of claim 1, wherein the controller is configured to, for anarray of predetermined rotor positions corresponding to eachpredetermined rotor position, energize more than one motor phase at anarray of predetermined current combinations and receive, from the staticload cell, a resultant static torque for each of the predeterminedcurrent combinations.
 7. The apparatus of claim 6, wherein thecontroller is configured to, for each predetermined rotor position and apredetermined first motor phase current, vary an additional motor phasecurrent or any suitable combinations of additional phase currents. 8.The apparatus of claim 6, wherein the controller is configured togenerate torque values from the resultant static torque and map thetorque values and associated phase current combinations for eachpredetermined rotor position to form the array of motor operational datalook up tables.
 9. A method for characterizing the relationship betweentorque, current and position of a brushless electric machine, the methodcomprising: coupling a static load cell to an output shaft of abrushless electric machine; generating an array of static torques on theoutput shaft with the brushless electric machine, the output shaft beingheld static by the static load cell; adjusting a rotor position of thebrushless electric machine; selecting, with a controller, adjacentphases of the brushless electric machine from all respective motorphases of the brushless electric machine and energizing the selectedadjacent phases; and recording, with the controller, motor data thatincludes a static torque value, rotor position, and phase currents forthe selected adjacent phases of the brushless electric machine.
 10. Themethod of claim 9, wherein an array of phase current combinations arerecorded for more than one phase for each static torque value in thearray of static torques.
 11. The method of claim 9, wherein an array ofstatic torques is generated for each rotor position in an array of rotorpositions.
 12. The method of claim 11, further comprising mapping, withthe controller, the array of static torques and respective phase currentcombinations for each rotor position to form a data look up table. 13.The method of claim 9, further comprising energizing, with thecontroller, the selected motor phases at an array of predeterminedcurrent combinations for an array of predetermined rotor positions andrecording resultant static torque values for each of the predeterminedcurrent combinations and corresponding rotor positions.
 14. A brushlesselectric machine load mapping apparatus comprising: a frame; aninterface disposed on the frame configured for mounting a brushlesselectric machine; a static load cell mounted to the frame separate anddistinct from the brushless electric machine and coupled to thebrushless electric machine; and a controller communicably coupled to thestatic load cell and the brushless electric machine, the controllerbeing configured to register with the controller a static motor torque,generated by the energized at least one motor phase of the brushlesselectric machine, statically reacted by and at the static load cellcorresponding to a section of the at least one motor phase so as todescribe a relation between values of the static motor torque, withrespect to a motor rotor position and a respective phase current foreach of the selected at least one motor phase of the brushless electricmachine in operation.
 15. The apparatus of claim 14, wherein at leastthe static load cell generates motor operational data, including atleast one of the static motor torque, the respective phase current foreach of the at least one respective motor phase and the motor rotorposition, for mapping and generating motor operational data look uptables.
 16. The apparatus of claim 15, wherein the controller receivesthe motor operational data from at least the static load cell formapping and generating the motor operational data look up tables. 17.The apparatus of claim 14, wherein the controller is configured toreceive motor operational data from the static load cell and thebrushless electric machine where the motor operational data includes atleast one of the static motor torque, the respective phase current foreach of the at least one respective motor phase and the motor rotorposition.
 18. The apparatus of claim 14, wherein the controller isconfigured to generate from motor operational data constant torquevalues as a function of the motor rotor position and phase currents foradjacent motor phases.
 19. The apparatus of claim 18, wherein thecontroller is configured to generate minimum power values associatedwith each constant torque value and provide the minimum power values ina look up table.
 20. The apparatus of claim 14, wherein the controlleris configured to generate motor operational data look up tables whereeach motor operational data look up table includes an array of constanttorque values and corresponding phase currents for a given rotorposition.